A Flashing Connector

ABSTRACT

An elongate connector for connecting a first building panel and second building panel, the connector comprising: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, the recess being arranged to receive a load bearing member positioned above the first building panel and wherein the top wall and side walls are arranged to be received into a channel of the second building panel thereby positioning and inter-connecting the second building panel above the first building panel; a flashing portion extending along the length of one of the side walls, said flashing portion depending downwardly from one of said side walls to lap over an edge portion of said one of the building panels.

TECHNICAL FIELD

This invention relates generally to building construction, and deals more particularly with a flashing connector used in a building system using modular components that allow quick and economical construction of buildings.

BACKGROUND

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

It is often necessary to fix building panels during construction of multi-level buildings. This presents a problem in that the point of contact between two building panels may provide an area where rainwater is able to enter the building and, over time, cause rot or other damage to internal wall framing, etc. It is accordingly desirable to address this problem, or to provide the public with a useful choice.

SUMMARY OF INVENTION

In one aspect, the invention provides an elongate connector for inter-connecting a first building panel below a second building panel, the connector comprising:

a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, the recess being arranged to receive a load bearing member positioned above the first building panel and wherein the top wall and side walls are arranged to be received into a channel of the second building panel thereby positioning and inter-connecting the second building panel above the first building panel;

a flashing portion extending along the length of one of the side walls, said flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels.

In an embodiment, the elongate connector further comprises a joining portion extending transversely relative to said one of the side walls and wherein the flashing portion depends downwardly relative to the joining portion.

In an embodiment, the joining portion extends substantially along the length of the elongate connector.

In an embodiment, the joining portion is angled to be substantially perpendicular relative to the said side wall and/or flashing portion.

In an embodiment, each of said spaced apart side walls are substantially parallel to each other.

In an embodiment, the top wall is transversely oriented relative to said side walls to define said recess.

In an embodiment, the top wall is substantially perpendicular to one or both of said side walls.

In an embodiment, a plane of the flashing portion is sufficiently spaced away from a plane of the said side wall to accommodate the top edge portion of one of the building panels positioned thereunder.

In an embodiment, spacing between the side walls is substantially less than the length of the connector.

In an embodiment, the side walls, top wall and the flashing portion are integrally formed from sheet metal.

In an embodiment, the joining portion is integrally formed with the side wall and the flashing portion.

In another aspect, the invention provides a method of construction for inter-connecting a first building panel below a second building panel in a multi-story building, at least the first building panel having two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the panel comprises a length (l₁) and a height (h₂) wherein top and bottom channel members face outwardly and extend along the length (l₁) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (h₁) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively, the method comprising the steps of:

positioning a load bearing member into the top channel of the first building panel to support the second building panel to be positioned above the first building panel;

positioning a flashing connector above an upper portion of the load bearing member wherein the flashing connector comprises: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, and a flashing portion depending downwardly from one of said side walls;

arranging the recess of said flashing connector to receive the upper portion of the load bearing member positioned above the first building panel and simultaneously position the flashing portion to lap over a top edge portion of the first building panel; and

positioning the second building panel above the top wall of the flashing connector thereby interconnecting the first and second building panels.

In an embodiment, the method of construction further comprises the step of positioning the flashing portion over a top edge of one of said spaced apart sheets of the first building panel positioned thereunder.

In an embodiment, the second building panel positioned above the first building panel also comprises two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the second panel comprises a length (l₂) and a height (h₂) wherein top and bottom channel members face outwardly and extend along the length (l₂) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (h₂) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively.

In an embodiment, the method comprising the step of: positioning the bottom channel of the second building panel to receive the top wall and an upper portion of the side walls of the flashing connector thereby inter-connecting the second building panel above the first building panel.

In yet another aspect, the invention provides a method of bending sheet metal to form an elongate flashing connector, the method comprising the steps of:

bending sheet metal to form two opposing wide walls separated by a top wall such that at least one of the side walls has a greater height than the other of said side wall to define a recess to receive a load bearing member positioned above a first building panel and wherein the top wall and side walls are arranged to be received into a channel of a second building panel thereby positioning and inter-connecting the second building panel above the first building panel; and

bending a lower portion of said at least one side wall with the greater height to extend transversely relative to the side wall and further form a downwardly dependent flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

FIG. 1 is a perspective in-use view of the flashing connector 100.

FIG. 1 a is a perspective view of a panel 1000 which is suitable for use as the top panel TP or the bottom panel BP.

FIG. 2 is an isolated view of the flashing connector 100 and the load bearing top plate 500.

FIG. 3A is an exploded sectional view of the flashing connector 100 shown in an in-use configuration for inter-connecting a top panel TP and a bottom panel BP.

FIG. 3B is a sectional in-use view of the flashing connector 100 shown in an in-use configuration for inter-connecting a top panel TP and a bottom panel BP.

FIG. 3C is an enlarged view of the flashing portion 140 extending along a side wall 120 of the flashing connector 100 shown in an in-use configuration.

FIG. 4 shows another exploded sectional view of the flashing connector 100 shown in an in-use configuration for inter-connecting a top panel TP and a bottom panel BP whereby fasteners F have been used to fasten the top panel TP and bottom panel BP to the flashing connector 100 and the load bearing top plate 500.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIGS. 1 to 4, a flashing connector 100 is illustrated. The flashing connector 100 (as shown in FIGS. 1 and 3 to 4) is used for interconnecting a top building panel TP and a bottom building panel BP. Each of the top panel and the bottom panel may be in the form of a panel 1000 shown in FIG. 1 a.

FIG. 1a illustrates a panel assembly 10 for a modular building system. The panel assembly 10 includes a rectangular building panel 100 with four channel elements 200, 205, 210 and 215 that are positioned along respective edge portions of the panel 1000. Specifically, the panel assembly 10 includes a top channel element 200, a bottom channel element 205 and two opposed side channel elements 210 and 215.

A typical panel 1000 comprises a core of fire resistant expanded polystyrene that is sandwiched between two sheets. The sheets may be made from any known construction material that is preferably lightweight, fire-resistant and provides insulation.

The panel may be provided in a range of sizes. By way of example, the width of the panel may be about 300 mm-1100 mm and the height of panel may be 2400 mm, 2700 mm or 3000 mm. The panel 1000 is an internal wall panel which is symmetrical about a vertical axis such that any panel can be turned upside down or back to front. As previously discussed, channel elements 200, 205, 210 and 215 extend along perpendicular edges of the panel 1000. Each channel element 200 has a substantially c-shaped cross section and is typically glued to the core (not shown) and the sheets 105, 110 of the panel 1000 providing increased structural integrity of the panel 1000.

Each flashing connector 100 comprises a hollow and elongate recess 150 defined by two spaced apart side walls 110 and 120 that are separated by a top wall 130. Referring to FIGS. 3A, 3B it is clearly shown that the top wall 130 and the spaced apart side walls 110 and 120 define the C-shaped recess 150. During construction of multi-level buildings, a load bearing member in the form of a load bearing top plate 500 is arranged into the top channel 200 of the one or more bottom panels BP (BP1, BP2 and BP3 shown in FIG. 1). The top plate 500 supports the construction of an additional floor and allows the top building panels TP (TP1, TP2 and TP3; shown in FIG. 1) in the multi-level building.

It is important to note that the dimensions and shape of the top plate 500 may vary in accordance with the load bearing requirements of the building. By way of example, the height and width of the top plate 500 may be varied in accordance with the load bearing requirements of the building. Whilst, the shape of the top plate 500 is shown to be square or rectangular, the shape of the load bearing is not limiting. Consequently, the shape of the recess defined by the side walls 110, 120 and the top wall 130 may also be varied without departing from the spirit and scope of the invention.

Once the top plate 500 has been positioned into the top channel 200, the flashing connector 100 is positioned above the top plate 500 such that at least an upper portion of the top plate 500 is received into the recess 150 of the flashing connector 100. Once the flashing connector 100 has been positioned above the top plate 500, the next step involves positioning the top panel TP above the bottom panel BP. Specifically, the top wall 130 of the flashing connector 100 and a substantial part of the side walls 110 and 120 are received into the bottom channel 205 of the top panel TP. FIG. 3A illustrates an exploded view and FIG. 3B illustrates a sectional view of the flashing connector 100 shown in an in-use configuration.

Whilst the preferred embodiment illustrates the use of building panels BP and TP having identical structural features, such a limitation is not limiting. By way of example, the one or both the top and building panels may have slightly different structural dimensions to suit specific building requirements.

Referring to FIG. 3C, the enlarged view of the flashing connector 100 illustrates a flashing portion 140 extending along the length of second side wall 120. The flashing connector 100 includes a joining portion 115 that extends transversely and outwardly relative to side wall 120 with a the downwardly dependent flashing portion 140 depending downwardly from an outwardly extending end of the joining portion 115 to lap around a top edge portion of an external sheet S of the bottom panel BP (See FIG. 3C). The width of the joining portion 115 needs to be slightly greater than the thickness of the sheet S to enable the flashing portion 140 to lap over the top edge of the sheet S. Once again, exact dimensions for the width of the joining portion 115 may vary to suit specific dimensions of the sheet S used in the lower building panel BP.

The flashing portion 140 extends along the entire length of the second side wall 120 and prevents rain water from entering the exposed region between the top panel TP and the bottom panel BP thereby preventing rot or other damage to internal wall framing of the building. Referring to FIG. 4, during construction, fasteners such as screws F may be used for fastening each of the top panel TP and the bottom panel BP onto the flashing connector 100. A first set of fasteners may be used to fasten the top panel TP onto the side walls of 110 and 120 and the top plate 500. Specifically, a drill may be used to drill the screws through the outer sheets of the top panel TP and through the side walls 110 and 120 into the top plate 500. A second set of fasteners may be used for fastening the outer sheets of the bottom panel BP with the top plate 500.

The flashing connector 100 may be formed from sheet metal such that each of the side walls 110, 120, top wall 130, the joining portion 115 and the flashing portion 140 are integrally formed by bending sheet metal. Sheet metal is a commonly used material for a multitude of applications including housings and casings, interior and exterior structures, and various covers and supports. Stock sheet metal may be supplied a manufacturer in the form of flat sheets or rolls of flat stock. The manufacturer may uses the stock metal sheet and cut the metal sheet by initially cutting the metal sheet to have a width and a length such that the length is substantially greater than the width to form a rectangular piece of sheet metal. The rectangular piece of sheet metal may be initially bent along its length to form the two opposing wide walls 110 and 12 separated by a top wall 130 such that the side walls 110 and 120 depend downwardly from the top wall 130. After the initial bending step, side wall 120 has a greater height than the other of said side wall 110 to define the recess 150 that can receive a load bearing member 500 positioned above a first building panel BP as has been previously described. The next step would involve bending a lower portion of side wall 120 to extend transversely relative to the side wall 120 to form the joining portion 115 and further form a downwardly dependent flashing portion 140 to lap over a top edge portion of said one of the building panels.

The bending steps for bending the sheet metal may be accomplished using either hand tools and/or forms, or bending machines including press and box brakes, and roll embossing machines, depending on the type of bend being performed and the desired results. Computers may also be used to control the metal-forming and metal cutting machines quickly and accurately. One such computer-controlled machine is a laser cutter wherein a laser beam of high energy is controlled by a computer and guided along one surface of metal sheet. The laser energy quickly and accurately cuts or etches the metal sheet, as controlled by the computer and as prescribed by software. Another type of cutting and etching machine uses a powerful stream of water, usually including an abrasive. The resulting water-jet is carefully controlled to abrade through metal sheet. The water-jet system allows for accurate cut lines or etched lines having a prescribed depth. Another software-driven technique may involves scribing or milling the metal with a hard cutting tool driven by a computer.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.

It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art. 

What is claimed:
 1. An elongate connector for inter-connecting a first building panel below a second building panel, the connector comprising: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, the recess being arranged to receive a load bearing member positioned above the first building panel and wherein the top wall and side walls are arranged to be received into a channel of the second building panel thereby positioning and inter-connecting the second building panel above the first building panel; a flashing portion extending along the length of one of the side walls, said flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels.
 2. An elongate connector in accordance with claim 1 further comprises a joining portion extending transversely relative to said one of the side walls and wherein the flashing portion depends downwardly relative to the joining portion.
 3. An elongate connector in accordance with claim 2 wherein the joining portion extends substantially along the length of the elongate connector.
 4. An elongate connector in accordance with claim 2 wherein the joining portion is angled to be substantially perpendicular relative to the said side wall and/or flashing portion.
 5. An elongate connector in accordance with claim 1 wherein each of said spaced apart side walls are substantially parallel to each other.
 6. An elongate connector in accordance with claim 1 wherein the top wall is transversely oriented relative to said side walls to define said recess.
 7. An elongate connector in accordance with claim 6 wherein the top wall is substantially perpendicular to one or both of said side walls.
 8. An elongate connector in accordance with claim 1 wherein a plane of the flashing portion is sufficiently spaced away from a plane of the said side wall to accommodate the top edge portion of one of the building panels positioned thereunder.
 9. An elongate connector in accordance with claim 1 wherein spacing between the side walls is substantially less than the length of the connector.
 10. An elongate connector in accordance with claim 1 wherein the side walls, top wall and the flashing portion are integrally formed from sheet metal.
 11. An elongate connector in accordance with claim 10 when dependent upon claim 2 wherein the joining portion is integrally formed with the side wall and the flashing portion.
 12. A method of construction for inter-connecting a first building panel below a second building panel in a multi-story building, at least the first building panel having two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the panel comprises a length (l₁) and a height (h₂) wherein top and bottom channel members face outwardly and extend along the length (l₁) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (h₁) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively, the method comprising the steps of: positioning a load bearing member into the top channel of the first building panel to support the second building panel to be positioned above the first building panel; positioning a flashing connector above an upper portion of the load bearing member wherein the flashing connector comprises: a hollow and elongate recess defined by two spaced apart side walls separated by a top wall, said side walls and top wall having a length extending between two ends of elongate connector, and a flashing portion depending downwardly from one of said side walls; arranging the recess of said flashing connector to receive the upper portion of the load bearing member positioned above the first building panel and simultaneously position the flashing portion to lap over a top edge portion of the first building panel; and positioning the second building panel above the top wall of the flashing connector thereby interconnecting the first and second building panels.
 13. A method of construction in accordance with claim 12 further comprising the step of positioning the flashing portion over a top edge of one of said spaced apart sheets of the first building panel positioned thereunder.
 14. A method of construction in accordance with claim 12 wherein the second building panel positioned above the first building panel also comprises two spaced apart sheets; an insulating core portion positioned between said spaced apart sheets, wherein edge portions of the spaced apart sheets define a hollow cavity, the cavity extending along peripheral portions of the panel wherein the second panel comprises a length (l₂) and a height (h₂) wherein top and bottom channel members face outwardly and extend along the length (l₂) of the panel and are positioned in respective hollow cavities along in-use top and bottom peripheral portions of the panel respectively; and wherein first and second opposite side channels face outwardly and extend along the height (h₂) of the panel and are positioned in respective hollow cavities along each of the lateral peripheral portions of the panel respectively, the method comprising the step of: positioning the bottom channel of the second building panel to receive the top wall and an upper portion of the side walls of the flashing connector thereby inter-connecting the second building panel above the first building panel.
 15. A method of bending sheet metal to form an elongate flashing connector, the method comprising the steps of: bending sheet metal to form two opposing wide walls separated by a top wall such that at least one of the side walls has a greater height than the other of said side wall to define a recess to receive a load bearing member positioned above a first building panel and wherein the top wall and side walls are arranged to be received into a channel of a second building panel thereby positioning and inter-connecting the second building panel above the first building panel; and bending a lower portion of said at least one side wall with the greater height to extend transversely relative to the side wall and further form a downwardly dependent flashing portion depending downwardly from one of said side walls to lap over a top edge portion of said one of the building panels. 